Finished slot and adjustable shirt collar and method of manufacturing same

ABSTRACT

An adjustable collar having a finished slot through which a fabric strip passes unimpeded. A pair of flaps is formed by an outer band of the collar and abut the finished slot. The fabric strip is secured to a free end of an elastic strip, which is secured to a shirt band at a first end of the elastic strip. A button is secured to a free end of the fabric strip and the button passes through a horizontal buttonhole defined in an end of an outer portion of a neckband of the shirt. The fabric strip is retracted and hidden when the collar is open. The button is larger than a diameter of the finished slot to prevent the fabric strip from retracting completely therethrough.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part application of application Ser. No.10/842,556, filed May 11, 2004 now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a finished slot and an adjustable shirtcollar and a method of manufacturing the same. More particularly, thepresent invention related to a finished slot that works in cooperationwith an elastic strip that self-adjusts a circumference of the shirtcollar to provide a comfortable fit while simultaneously providing theshirt collar with an opening that is more secure, better quality, andhas a longer life.

2. Description of Related Art

There are occasions when people need to expand the collar of the shirtthey are wearing to obtain a comfortable fit. Shirts with permanentlyattached collars, particularly dress shirts, are normally manufacturedin standard collar sizes based on the circumference of the collar.Although standard collar sizes may initially provide a comfortable fit,many individuals who fall between standard collar sizes or experience achange in weight over time may experience discomfort when wearing theshirt. Moreover, it is well known that clothing, i.e., shirts, shrinkafter several washings, which also results in a change in the actualsize of the shirt collar, whereupon, it becomes uncomfortable to wearthe shirt. Therefore, an adjustable shirt collar becomes necessary toensure that shirts may adjust to fit the wearer comfortably.

Various solutions to this problem have been offered in the art. Oneknown solution offers collar adjustment using an adjustable shirt collarfastening device having an elastic strip secured between the lining andthe ply of the collar by stitches. A button is attached at the end ofthe elastic strip, which is maneuverable so as to pass through ahorizontal buttonhole in the collar. Additionally, a U-shaped metal capis adapted to prevent the elastic strip from inadvertently entering orbeing drawn into or through the horizontal buttonhole. A finished fabricstrip folds over the elastic strip and the button. Although thissolution offers collar expansion, a wearer may desire to conceal theelastic strip if the top button is unbuttoned to provide a neater andarguably more professional appearance.

Another known solution is a shirt having a fixed unit, which contains arelatively short and resilient strap vertically disposed and bent backonto itself. A button is attached to the end of the strap by stitching.Additionally, two tabs of the collar shift together allowing the buttonto pass through a buttonhole to hold the tabs together. The collarextends when the strap is stretched outwardly through the opening of theinner tab and through the buttonhole. The strap is oriented orthogonallyrelative to the collar band. Therefore, to relieve discomfort, thecollar is adjusted by stretching the strap outwardly through thehorizontal buttonhole. Because such adjustment is due to a force thatpulls the button and the strap outward rather than the more naturalside-to-side movement of the button and strap, the fit may still beuncomfortable as the button presses against the front center portion ofa wearer's throat. Moreover, because the strap is attached orthogonallyrelative to a longitudinal axis of the buttonhole, any sideways movementof the strap results in the button loosening, or the alteration of thestitching holding the strap to the collar, or both.

Other solutions are disclosed by U.S. Pat. No. 912,958 to H. S. Hawks;U.S. Pat. No. 1,879,527 to J. Sansone; and U.S. Pat. No. 3,142,843 to S.Berger. Each patent describes a collar button structured to relievepressure on the neck of the wearer without using an expanding strip.

Additionally, U.S. Pat. No. 6,212,686 to Krause et al., as well as U.S.Pat. Nos. 5,898,941 and 6,250,116 to Groshens disclose solutions usingexpandable fabric weaves, expandable fabric patterns, expandable fabricweaves and patterns, or stitching in the collar to provide the necessaryexpansion.

U.S. Pat. No. 5,692,240 to Steele discloses another solution wherein thestationary collar button is replaced with adjustable hook and loopfasteners adapted for removable attachment to one another. A third hookand loop fastener strip allows the covering strip to be retracted andattached for concealment. However, the solution taught by Steelerequires several manufacturing steps that result in a substantialincrease in manufacturing costs, which are passed along to consumers.Additionally, the hook and loop fasteners become less effective aftermultiple washings because the hook and loop fasteners ability tolockingly engage is impeded by the friction that occurs during thewashing process. Furthermore, it is well known that the hook and loopfasteners inadvertently attach to other items that may cause a build upof threads or particles, which reduces the effectiveness or theaesthetic appearance of the fasteners.

U.S. Pat. No. 3,828,365 to Berger merely discloses an expandablebuttonhole. Furthermore, U.S. Pat. No. 2,646,570 to E. Rinehart et al.discloses a shirt having an elastic cord covered with fabric. A loop atthe end of the elastic cord extends across the collar opening to attachto one of several buttons under the collar on the opposite side of thecollar.

In yet another example, U.S. Patent Application Publication No.2005/0022287 to Neff et al. (Neff) teaches an expandable collar assembly10 having parallel lines of stitching 32 and 34 that define a pocketbetween a collar band 16 and body 12 of the shirt. A slot 36 formed in amanner similar to a buttonhole is located in the pocket and an elongatedstrip of self fabric 42 extends through the slot 36 with a button 38attached to one end of the elongated strip of fabric 42. The other endof the elongated strip of fabric 42 is stitched to a square piece ofelastic 45. The other end of the square piece of elastic 45 is bartacked 48 to the body 12 of the shirt or the collar band 16.

Many of the solutions described above are susceptible to deteriorationor create constrictive pressure on the throat of the wearer.Additionally, the solutions do not allow the wearer to conceal theapparatus when the collar is unbuttoned and left open. Furthermore, thesolutions described above, in particular the teachings of Neff, sufferfrom the adjusting strip washing out and, because the slot 36 of Neff isformed like a buttonhole, the edges of the slot 36 fray due to thefriction created by the self fabric 42 repeatedly rubbing against theedges of the slot 36, as well as the shirt being constantly washed.

Therefore, there is a need for an expandable shirt collar that adjuststhe fit of the collar without placing undesirable and unnecessarypressure on the throat of the wearer, while providing a finished slotthat works in cooperation with an elastic strip that self-adjusts acircumference of the shirt collar. There is also a need for the finishedslot to be sturdy, and have edges that are resilient to the frictionthat is created by a strip of fabric that constantly rubs against theedges to provide a better quality and longer lasting adjustable orexpandable shirt collar. There is yet another need for the finished slotto provide a sturdy opening for the strip of fabric to pass through.There is a further need for an adjustable shirt collar that creates anappealing look and allows the wearer to conceal the apparatus of theexpandable shirt collar.

SUMMARY OF THE INVENTION

Aspects of the present invention provide a self-adjusting shirt collarthat provides a comfortable fit for the wearer.

One aspect of the present invention relates to a collar. The collarincludes a neckband assembly, a flap, an extendable elastic strip, afabric strip, a button, a horizontal buttonhole, and a finished fabricstrip slot (hereinafter referred to simply as the finished slot). Theelastic strip is secured to a neckband by stitching. The neckband hasthe finished slot secured near one end of the neckband. Moreover, thefabric strip is attached to a free end of the elastic strip and a buttonis secured to a free end of the fabric strip. A buttonhole is providedon an end of the neckband opposite the button end, such that thebuttonhole is configured to receive the button upon extending the fabricstrip outward through the finished slot. The fabric strip is covered andconcealed when retracted inward through the finished slot and not inuse.

In another aspect of the invention, the neckband assembly has an innerband and an outer band. The fabric strip extends from the outside of theouter band and through the finished slot, which allows the fabric stripto automatically be hidden when retracted. Also, the finished slotallows an operating length of the fabric strip to be adjusted, such as,for example, to increase the circumference of the collar.

In yet another aspect of the present invention, the finished slot isformed by folding a button end of the outer band back onto itself, i.e.,onto an outer or first side thereof, to define a vertically extendingfolded edge. A pair of short stitches is sewn into the outer bandparallel to the folded edge. One of the short stitches extends from abottom edge of the outer band and extends upward while the other shortstitch extends from a top edge of the outer band and extends downward,wherein free ends of the short stitches oppose each other across apredetermined distance that defines a region which forms the slot.

A cut is then made along the fold of the folded edge to form two flaps,i.e., first and second flaps, and an end piece of the outer band isfolded back flat towards the inner or second side of the outer band. Oneof the flaps, i.e., the first flap, is then folded onto the second orinner side of the outer band such that the first and second flaps areflat. A pair of vertically extending stitches is then sewn onto theflaps, each vertically extending stitch extends from the bottom edge ofthe outer band to the top edge thereof on either side of the slot tosecure the flaps to the outer band and define the slot therebetween. Theslot is defined by cutting a hole sized to permit the fabric strip topass therethrough, the hole being formed in the region between theopposing ends of the short stitches.

The resulting finished slot is stronger and more secure thanconventional buttonhole type openings that are prevalent in collars,resistant to fraying with repeated use, and less inclined to wash out.Furthermore, the adjustable collar with the finished slot is moredurable, better quality, and provides the shirt with an adjustablecollar having a longer life.

It should be noted that in one embodiment, the top and bottom corners ofeach flap are cut to provide a clean edge. In yet another embodiment, afusible interlining may be joined to the inner or second side of theouter band, wherein a slot is formed in the interlining corresponding tothe slot formed in the outer band.

The extendable elastic and fabric strips are then attached to the innerband. As such, the fabric strip is able to slide through the finishedslot unimpeded so as to not place any constricting pressure on thethroat of the wearer. Moreover, the fabric strip does not place strainon the elastic strip or fabric strip stitching, which could eventuallydisengage the elastic strip or fabric strip, or both, from the collar.Moreover, because there is no interruption when maneuvering the fabricstrip through the finished slot, the wearer does not have toaggressively pull the button or the fabric strip to button the collar.As a result, the button stitching is not susceptible to loosening.Finally, the button is attached to prevent the fabric strip from beingdrawn inadvertently back through the finished slot and away from theouter side of the outer band.

Additional advantages and novel features of the present invention willbecome apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially transparent perspective view of a buttoned shirtwith an expandable collar, in accordance with one aspect of the presentinvention;

FIGS. 2A-2C are sketches illustrating the process of forming a finishedslot in an outer band of the expandable collar illustrated in FIG. 1;

FIG. 3 is an enlarged view of an open shirt collar with a retractedexpandable elastic strip, in accordance with one aspect of the presentinvention;

FIG. 4 is an enlarged view of an open shirt collar with the extendedexpandable elastic strip illustrated in FIG. 3;

FIG. 5 is a fragmentary view of one end of the shirt collar illustratedin FIG. 1; and

FIG. 6 is a rear (or outside) view of the fully opened shirt collar, inaccordance with one aspect of the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

As shown in FIGS. 1-6, the present invention includes an adjustableshirt collar 10 having an elastic strip 19, a fabric strip 14 attachedto the elastic strip 19, and a button 50 attached to an end of thefabric strip 14. The present invention, as disclosed herein, allows forself-adjustment of the circumference of the shirt collar 10 to provide acomfortable fit to the wearer.

In particular, FIG. 1 illustrates a shirt 1 having the collar 10 sewnthereon. The collar 10 includes a multi-layered neckband assembly 20 anda multi-layered flap 30, which may fold up or down over a crease 40between the neckband assembly 20 and the flap 30. It is within the scopeof the invention to form the crease 40 between the neckband assembly 20and the flap 30 by stitching the flap 30 to the neckband assembly 20.Furthermore, if the collar 10 is manufactured as a single (ormulti-layered) outer piece and inner piece of fabric, respectively, thecrease 40 is formed over a plane between the neckband assembly 20 andthe flap 30.

Additionally, the neckband assembly 20, as shown in FIGS. 1-4, includesan outer band 21 and inner band 22 with a finished fabric strip slot 25defined at a first end 21a of the outer band 21. The finished slot 25defines an opening that is vertical relative to a buttonhole 28 definedat a second free end 21b of the outer band 21. See FIGS. 1-4 and 6. Thebuttonhole 28 is horizontal and has a longitudinal axis extending in adirection substantially parallel relative to a longitudinal axis of theneckband assembly 20. Furthermore, as shown in FIGS. 1-5, the finishedslot 25 has a longitudinal axis extending orthogonally relative to thelongitudinal axis of the horizontal buttonhole 28 and neckband assembly20.

FIGS. 2A-2C are sketches illustrating the process in which the finishedslot 25 is formed in the first end 21a of the outer band 21.

Referring to FIGS. 2A-2B, the outer band 21 includes an outer or firstsurface 121 and an inner or second surface 221 on the opposite side ofthe band 21. The outer surface 121 faces away from the wearer while theinner surface 221 faces toward the inner band 22 and the wearer. Thefirst end 21a of the outer band 21 is folded back onto the outer surface121 thereof, to define a vertically extending folded edge 101 and exposethe inner surface 221 of the outer band 21 at a region including thefirst end 21a.

A pair of short stitches 102, 103 is sewn into the outer band 21parallel to the folded edge 101. A first short stitch 102 of the pair ofshort stitches extends from a bottom edge 21d of the outer band 21upward toward an upper edge 21c of the outer band 21 while a secondshort stitch 103 extends from the upper edge 21c of the outer band 21downward toward a bottom edge 21d of the outer band 21. Free ends 102aand 103a of the short stitches 102 and 103, respectively, oppose eachother across a region 104 within which the finished slot 25 is to beformed. While the distance which the stitches 102 and 103 extend towardeach other may vary depending on factors such as the height of the outerband 21, it should be noted that the length of the region 104 must besized or configured to permit the slot 25 to be formed therein such thatthe slot 25 permits the fabric strip 14 to pass therethrough yetprohibit the button 50 attached to the end thereof from also passingtherethrough.

A vertical cut 105 is then made along the fold of the folded edge 101from the bottom edge 21d to the upper edge 21c or vice versa to form twoflaps, i.e., first flap 110 and second flap 120, and the first end piece21a of the outer band 21 is folded back towards the inner or second side221 of the outer band 21 to be flat. The first flap 110 is then foldedover the cut 105 onto the second or inner side 221 of the outer band 21such that the first flap 110 and the second flap 120 are flat relativeto the second or inner side 221.

Vertically extending stitches 113 and 123 are then sewn onto acorresponding flap 110 and 120, respectively, wherein each verticallyextending stitch 113 and 123 extends from the bottom edge 21d of theouter band 21 to the top edge 21c thereof. The vertically extendingstitches 113 and 123 secure the flaps 110 and 120, respectively, to theouter band 21. The finished slot 25 is then formed, preferably bycutting or any other suitable manner, between the vertically extendingstitches 113 and 123 and in the region 104 defined between the opposingends 102a and 103a of the short stitches 102 and 103. It should be notedthat it is within the scope of the present invention for the free end102a of the short stitch 102 to abut a lower portion 25a of the slot 25while the free end 103a of the short stitch 103 abuts the upper portion25b of the slot 25. Therefore, the short stitches 102 and 103, as wellas the vertically extending stitches 113 and 123 help provide a finishedslot 25 that is more secure, better looking, stronger, and less likelyto wash out or fray with repeated passing of the fabric strip 14therethrough.

It should be noted that while it has been described herein for the firstend 21a of the outer band 21, and the flaps 110 and 120 are stitched tothe outer band 21, it is within the scope of the present invention forthe end 21a and flaps 110 and 120 to be attached to the outer band byany known or later developed manner, such as, for example only, by usingan adhesive.

It should be noted that in one embodiment, a top corner 110a and 120aand a bottom corner 110b and 120b of each flaps 110 and 120 are formed,preferably by cutting the flaps 110 and 120, to provide a clean edge.See FIG. 2B.

In yet another embodiment, as shown in FIG. 2C, a fusible interlining321 may be joined to the inner or second side 221 of the outer band 21,wherein a slot 325 is formed in the interlining 321 which corresponds toor is aligned with the slot 25 formed in the outer band 21.

Referring to FIG. 4, the elastic strip 19, is sewn using at least twobartacks to the underside of the outer band 21 prior to attaching theouter band 21 and inner band 22 together, along with the flap 30 tocomplete assembly of the adjustable shirt collar 10. The fabric strip14, as shown in FIGS. 1-6 and particularly FIG. 5, is inserted from theoutside into finished slot 25 at the first free end 21a of the outerband 21 until the button 50 contacts slot 25. It should be noted thatthe free end 19a of elastic strip 19 is sewn with at least two bartacksto the free end 14b of the fabric strip 14 and the button 50 is sewn onthe free end 14a of the fabric strip 14 before the fabric strip 14 ispassed through the slot 25. The button 50 may also pass through thehorizontal buttonhole 28 to close the shirt collar 10. Moreover, thebutton 50 prevents the fabric strip 14 from inadvertently being drawnthrough the vertical finished slot 25.

The fabric strip 14, which is attached to the collar 10 by the elasticstrip 19, may be manufactured in any color, design or material, e.g.,plaid, satin, or the same color and material as the wearer's tie, butparticularly, in the same color and of the same material as the shirt 1.The fabric strip 14 extends along the length of the collar 10 when thewearer grasps the button 50 and inserts the button 50 through thehorizontal buttonhole 28 such that the second end 21b overlaps the firstend 21a of the outer band 21. See FIGS. 1 and 3-4. The fabric strip 14is hidden inside the outer band 21 and inner band 22 when the fabricstrip 14 is retracted.

The elastic strip 19 and fabric strip 14, when attached to the collar 10through the vertical finished slot 25, functions to expand thecircumference of the neckband assembly 20, as needed, when the fabricstrip 14 is buttoned into the horizontal buttonhole 28. By expanding thecircumference of the neckband assembly 20, the wearer may maximize thecomfort of the shirt collar 10.

Additionally, many modifications may be made to adapt the teachings ofthe expandable collar of this invention to particular situations ormaterials without departing from the scope thereof. For example, whilethe flaps 110 and 120 are discussed above as extending vertically fromthe bottom edge 21d to the upper edge 21c of the outer band 21, it isenvisioned that the flaps 110 and 120 extend a length corresponding to aheight of the slot 25. Therefore, this invention should not be limitedto the particular embodiments disclosed herein, but includes allembodiments within the spirit and scope of the disclosure.

What is claimed is:
 1. An adjustable collar of a shirt, the collarcomprising: a neckband assembly, having a first end and a second end,extends along a circumference of the collar and comprises an outer bandand an inner band, the outer band having an inner side facing the innerband; an extendable elastic strip having a first end secured to anunderside of the outer band and which extends through toward a finishedslot defined in the first end of the outer band; a fabric strip having afirst end secured to a free end of the elastic strip; a button securedto a free end of the fabric strip; a buttonhole defined in the secondend of the neckband assembly and configured to receive the button uponextension of the elastic and fabric strip assembly; and a pair of flapsdefined only by a first portion of the inner side of the outer bandengaging a second portion of the inner side of the outer band, whereinonly the pair of flaps define the finished slot by abutting each other.2. The adjustable collar according to claim 1, wherein the outer bandfurther includes an outer side facing away from a direction in which theinner side faces.
 3. The adjustable collar according to claim 2, whereinthe flaps are formed on the inner side of the outer band.
 4. Theadjustable collar according to claim 3, wherein the flaps are affixed tothe inner side of the outer band by fixing means.
 5. The adjustablecollar according to claim 4, wherein the fixing means include any one ofstitching and an adhesive.
 6. The adjustable collar according to claim1, wherein each flap is affixed to the outer band by stitching extendingin a direction parallel to a longitudinal axis of the finished slot. 7.The adjustable collar according to claim 1, wherein the flaps extendfrom a bottom edge of the outer band to an upper edge of the outer band.8. The adjustable collar according to claim 1, wherein first stitchingextends from an upper portion of the finished slot to an upper edge ofthe outer band and second stitching extends from a bottom portion of thefinished slot to a lower edge of the outer band.
 9. The adjustablecollar according to claim 1, wherein at least one of an upper corner anda lower corner of each flap is cut to provide each flap with at leastfive sides.
 10. The adjustable collar according to claim 9, wherein thecut upper and lower corners are located remotest relative to thefinished slot.
 11. The adjustable collar according to claim 1, wherein afusable interlining band is affixed to an inner side of the outer band.12. The adjustable collar according to claim 11, wherein the fusableinterlining band includes an interlining slot that is aligned with thefinished slot of the outer band.
 13. The adjustable collar according toclaim 1, wherein the finished slot extends in a vertical direction thatis orthogonal relative to a longitudinal axis of the elastic and fabricstrip assembly.
 14. The adjustable collar according to claim 1, whereina diameter of the button is larger than a diameter of the finished slot,and wherein the button is prevented from passing through the finishedslot.
 15. The adjustable collar according to claim 1, wherein the firstend of the elastic strip is secured to an inner side of the outer bandby bar tacking.
 16. The adjustable collar according to claim 1, whereinthe first end of the fabric strip is secured to the free end of theelastic strip by bar tacking.
 17. The adjustable collar according toclaim 1, wherein the second end of the outer band overlaps the first endof the outer band portion of the neckband assembly when the buttonpasses through the finished slot.